US7823632B2 - Method and apparatus for programmable robotic rotary mill cutting of multiple nested tubulars - Google Patents
Method and apparatus for programmable robotic rotary mill cutting of multiple nested tubulars Download PDFInfo
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- US7823632B2 US7823632B2 US12/540,924 US54092409A US7823632B2 US 7823632 B2 US7823632 B2 US 7823632B2 US 54092409 A US54092409 A US 54092409A US 7823632 B2 US7823632 B2 US 7823632B2
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Images
Classifications
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- E—FIXED CONSTRUCTIONS
- E21—EARTH OR ROCK DRILLING; MINING
- E21B—EARTH OR ROCK DRILLING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR A SLURRY OF MINERALS FROM WELLS
- E21B29/00—Cutting or destroying pipes, packers, plugs or wire lines, located in boreholes or wells, e.g. cutting of damaged pipes, of windows; Deforming of pipes in boreholes or wells; Reconditioning of well casings while in the ground
- E21B29/002—Cutting, e.g. milling, a pipe with a cutter rotating along the circumference of the pipe
- E21B29/005—Cutting, e.g. milling, a pipe with a cutter rotating along the circumference of the pipe with a radially-expansible cutter rotating inside the pipe, e.g. for cutting an annular window
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- E—FIXED CONSTRUCTIONS
- E21—EARTH OR ROCK DRILLING; MINING
- E21B—EARTH OR ROCK DRILLING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR A SLURRY OF MINERALS FROM WELLS
- E21B44/00—Automatic control systems specially adapted for drilling operations, i.e. self-operating systems which function to carry out or modify a drilling operation without intervention of a human operator, e.g. computer-controlled drilling systems; Systems specially adapted for monitoring a plurality of drilling variables or conditions
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T407/00—Cutters, for shaping
- Y10T407/19—Rotary cutting tool
- Y10T407/1946—Face or end mill
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T409/00—Gear cutting, milling, or planing
- Y10T409/30—Milling
- Y10T409/306664—Milling including means to infeed rotary cutter toward work
- Y10T409/307672—Angularly adjustable cutter head
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T82/00—Turning
- Y10T82/10—Process of turning
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T82/00—Turning
- Y10T82/12—Radially moving rotating tool inside bore
Definitions
- the present disclosure generally relates to methods and apparatus for mill cutting through wellbore tubulars, including casing or similar structures.
- An “inner” and “outer” string may be severable, if generally concentrically positioned in relation to each other. However, there is no current capability for severing a multiple non-concentrically (eccentrically) nested tubulars that provides consistent time and cost results in a single trip into the wellbore.
- the mechanical blade cutter When cutting multiple, nested tubulars of significant diameters, for example 9 5 ⁇ 8 inches outside diameter through 36 inches outside diameter, with at least two other nested tubulars of different sizes dispersed in between, the mechanical blade cutter must be brought back to the surface where successive larger cutting blades are exchanged for smaller cutting blades. Exchanging the smaller blades for larger blades allows the downhole cutting of successively larger diameter multiple, nested tubulars.
- the user To access the downhole mechanical blade cutter, the user must pull the entire work string out of the wellbore and unscrew each work string joint until the mechanical blade cutter is removed from the bottom of the work string. After exchanging the mechanical blade cutter for a larger cutting blade, the work string joints are screwed back together, one after another, and tripped back into the wellbore. The mechanical blade cutter trip back into the wellbore to the previous tubular cut location for additional cutting is compromised because the length of the work string varies due to temperature changes or occasionally human error in marking or counting work string joints. Consequently, it is difficult to precisely align successive cuts with earlier cuts.
- the remaining portion of the casing forms a “C” or horseshoe-type shape when viewed from above.
- the blade cutter extends to its fullest open cut position after moving across a less dense material or open space (because that material has been cut away) and when the blade cutter impacts the leading edge of the “C” shaped tubular, the force may break off the blade.
- the breaking of a cutter blade requires again tripping out and then back into the well and starting over at a different location in the wellbore in order to attempt severing of the multiple, nested tubulars.
- Non-concentric, multiple, nested tubulars present serious difficulties for mechanical blade cutters. Severing non-concentric multiple, nested tubulars may take a period of days for mechanical blade cutters.
- abrasive waterjet cutters also experience difficulties and failures to make cuts through multiple, nested tubulars.
- existing solutions relate to abrasive waterjet cutting utilizing rotational movement in a substantially horizontal plane to produce a circumferential cut in downhole tubulars.
- the prior art in abrasive waterjet cutters for casing severance often results in spiraling cuts with narrow kerfs in which the end point of the attempted circumferential cut fails to meet the beginning point of the cut after the cutting tool has made a full 360 degree turn. In other words, the cut does not maintain an accurate horizontal plane throughout the 360 degree turn, and complete severance fails to be achieved.
- Another problem encountered by existing abrasive waterjet cutting is the inability to cut all the way through the thicker, more widely spaced mass of non-concentrically positioned tubulars. In this situation, the cut fails to penetrate all the way through on a 360 degree circumferential turn.
- a further disadvantage of traditional abrasive waterjet cutting is that in order to successfully cut multiple, nested tubulars downhole, air must be pumped into the well bore to create an “air pocket” around the area where the cutting is to take place, such that the abrasive waterjet tool is not impeded by water or wellbore fluid. The presence of fluid in the cutting environment greatly limits the effectiveness of existing abrasive waterjet cutting.
- This invention provides a safe and environmentally benign means of completely severing multiple, nested tubulars for well abandonment including overcoming the difficulties encountered by mechanical blade cutting, abrasive waterjet cutting or other means of tubular milling currently available.
- This invention provides methodology and apparatus for efficiently severing installed multiple, nested strings of tubulars, either concentric or eccentric, as well as cement or other material in the annuli between the tubulars, in a single trip into a well bore in an environmentally sensitive manner without the need for a rig.
- the invention utilizes a computer-controlled robotic downhole rotary mill to effectively generate a shape(s) or profile(s) through, or completely sever in a 360 degree horizontal circumferential plane, the installed tubing, pipe, casing and liners as well as cement or other material that may be encountered in the annuli between the tubulars.
- This process occurs under programmable robotic, computerized control, making extensive use of digital sensor data to enable algorithmic, robotic actuation of the downhole assembly and robotic rotary mill cutter.
- the downhole assembly is deployed inside the innermost tubular to a predetermined location and, under computer control, a rotary mill cuts outward radially and vertically, cutting a void (or swath) and completely severing the installed tubing, pipe, casing and liners as well as cement or other material that may be encountered in the annuli between the tubulars. The complete severance process occurs during one trip into the well bore.
- this system is designed for precise W-axis movement in a 360 degree horizontal plane, due to the wide swath or void it generates when removing material in said horizontal plane, it does not require the exact alignment of the starting and ending points in the 360 degree cut that are otherwise required by traditional waterjet systems.
- Traditional narrow-kerf abrasive waterjet systems often create a “spiral” cut because of an inability to maintain perfect alignment from the starting point to the ending point. This “spiral” cut causes severance attempts to fail because the starting point of the cut and the ending point of the cut did not meet.
- the severed casing will drop vertically at the surface platform, providing visual verification of the severance.
- the reach of the cutter is designed to extend beyond the outermost casing with any number of additional tubulars inside this outermost casing being extremely eccentrically positioned. This solves the cutting “reach” problems that are encountered with abrasive waterjet cutting when the waterjet has difficulty cutting through the thickest, most widely spaced mass of the eccentrically positioned tubulars and cement.
- the programmable computer-controlled, sensor-actuated rotary milling process will take less time to complete severance than mechanical blade cutters or existing abrasive waterjet cutting.
- the actively adjusted rotary milling, profile generation process prevents the impact breakage that plagues mechanical blade cutters encountering non-concentric, multiple, nested tubulars.
- this invention's capability of being deployed and completing the severance in one trip downhole provides a significant advantage over prior art.
- a technical advantage of the disclosed subject matter is the complete severing of tubing, pipe, casing and liners, as well as cement or other material, that may be encountered in the annuli between the tubulars in a single trip down hole.
- Another technical advantage of the disclosed subject matter is providing visual verification of severance without employing additional equipment.
- Yet another technical advantage of the disclosed subject matter is creating a wide void (or swatch) thereby removing substantial material such that the start point and end point of the void (or swath) do not have to precisely align for complete severance.
- An additional technical advantage of the disclosed subject matter is avoiding repeat trips down hole because of cutter breakage.
- Another technical advantage of the disclosed subject matter is efficiently severing non-concentrically (eccentrically) aligned nested tubulars.
- Yet another technical advantage of the disclosed subject matter is accomplishing severance in less time and in an environmentally benign manner.
- Still another technical advantage is providing electronic feedback showing cutter position and severance progress.
- FIG. 1 depicts the robotic rotary mill cutter of the preferred embodiment.
- FIGS. 2A and 2B depict the upper and lower portions, respectively, of the robotic rotary mill cutter of the preferred embodiment.
- FIG. 3 depicts an expanded view of an inserted carbide mill of one embodiment.
- FIG. 4A depicts a top view of multiple casings (tubulars) that are non-concentric.
- FIG. 4B depicts an isometric view of non-concentric casings (tubulars).
- FIG. 5A depicts a portion of the robotic rotary mill cutter as it enters the tubulars.
- FIG. 5B depicts a portion of the robotic rotary mill cutter as it is severing multiple casings.
- casing(s) and tubular(s) are used interchangeably.
- This invention provides a method and apparatus for efficiently severing installed tubing, pipe, casing, and liners, as well as cement or other encountered material in the annuli between the tubulars, in one trip into a well bore.
- the method generally is comprised of the steps of positioning a robotic rotary mill cutter inside the innermost tubular in a pre-selected tubular or plurality of multiple, nested tubulars to be cut, simultaneously moving the rotary mill cutter in a predetermined programmed vertical X-axis, and also 360 degree horizontal rotary W-axis, as well as the spindle swing arm in a pivotal Y-axis arc.
- the vertical and horizontal movement pattern(s) and the spindle swing arm are capable of being performed independently of each other, or programmed and operated simultaneously in conjunction with each other.
- the robotic rotary mill cutter is directed and coordinated such that the predetermined pattern is cut through the innermost tubular beginning on the surface of said tubular with the cut proceeding through it to form a shape or window profile(s), or to cut through all installed multiple, nested tubulars into the formation beyond the outermost tubular.
- a profile generation system simultaneously moves the robotic rotary mill cutter in a vertical Z-axis, and a 360-degree horizontal rotary W-axis, and the milling spindle swing arm in a pivotal Y-axis arc to allow cutting the tubulars, cement, and formation rock in any programmed shape or window profile(s).
- the robotic rotary mill cutter apparatus is programmable to simultaneously or independently provide vertical X-axis movement, 360 degree horizontal rotary W-axis movement, and spindle swing arm pivotal Y-axis arc movement under computer control.
- a computer having a memory and operating pursuant to attendant software, stores shape or window profile(s) templates for cutting and is also capable of accepting inputs via a graphical user interface, thereby providing a system to program new shape or window profile(s) based on user criteria.
- the memory of the computer can be one or more of but not limited to RAM memory, flash memory, ROM memory, EPROM memory, EEPROM memory, registers, hard disk, a removable disk, a CD-ROM, floppy disk, DVD-R, CD-R disk or any other form of storage medium known in the art.
- the storage medium may be integral to the processor.
- the processor and the storage medium may reside in an ASIC or microchip.
- the computer controls the profile generation servo drive systems as well as the milling cutter speed.
- the robotic rotary mill cutter requires load data to be able to adjust for conditions that cannot be seen by the operator.
- the computer receives information from torque sensors (see 52 , and 53 of FIGS. 2A and 2B ) attached to Z-axis, W-axis, Y-axis, and milling spindle drive motor, and makes immediate adaptive adjustments to the feed rate and speed of the vertical Z-axis, the 360 degree horizontal rotary W-axis, the spindle swing arm pivotal Y-axis and the RPM of the milling spindle motor.
- Software in communication with sub-programs gathering information from the torque devices directs the computer, which in turns communicates with and monitors the downhole robotic rotary mill cutter and its attendant components, and provides feeds and speeds simultaneously or independently along the vertical Z-axis, the 360 degree horizontal rotary W-axis, as well as the pivotal spindle swing arm Y-axis arc movement.
- the shape or window profile(s) are programmed by the operator on a program logic controller (PLC), personal computer (PC), or a computer system designed or adapted for this specific use.
- PLC program logic controller
- PC personal computer
- GUI graphical user interface
- HMI Red Lion G3 Series
- the vertical Z-axis longitudinal computer-controlled servo axis uses a hydraulic cylinder, such as the Parker Series 2HX hydraulic cylinder, housing the MTS model M-series absolute analog sensor for ease of vertical Z-axis longitudinal movements, although other methods may be employed to provide up and down vertical movement of the robotic rotary mill cutter.
- a hydraulic cylinder such as the Parker Series 2HX hydraulic cylinder, housing the MTS model M-series absolute analog sensor for ease of vertical Z-axis longitudinal movements, although other methods may be employed to provide up and down vertical movement of the robotic rotary mill cutter.
- the vertical Z-axis longitudinal computer-controlled servo axis may be moved with a ball screw and either a hydraulic or electric motor, such as a computer controlled electric servo axis motor, the Fanuc D2100/150 servo, with encoder feedback to the computer system by an encoder (see 50 in FIG. 2A ) such as the BEI model H25D series incremental optical encoder.
- a hydraulic or electric motor such as a computer controlled electric servo axis motor, the Fanuc D2100/150 servo
- an encoder see 50 in FIG. 2A
- Servo motors and ball screws are known in the art and are widely available from many sources.
- the vertical Z-axis longitudinal computer-controlled servo axis may be moved with a rack and pinion, either electrically or hydraulically driven.
- Rack and pinion drives are known in the art and are widely available from many sources.
- the rotational computer controlled W-axis rotational movement is an electric servo motor, although other methods may be employed.
- the rotational computer-controlled W-axis servo motor such as a Fanuc model D2100/150 servo, provides 360-degree horizontal rotational movement of the robotic rotary mill cutter through a specially manufactured slewing gear.
- the Y-axis pivotal milling spindle swing arm computer-controlled servo axis uses a hydraulic cylinder for ease of use, although other methods may be employed.
- the Y-axis pivotal milling spindle swing arm computer-controlled servo axis may utilize the Parker Series 2HX hydraulic cylinder, housing the MTS model M-series absolute analog sensor (see 51 in FIG. 2B ) inside the hydraulic cylinder to provide position feedback to the computer controller for pivotal spindle swing arm Y-axis arc movement.
- an inertia reference system such as, Clymer Technologies model Terrella6 v2
- FIG. 1 depicts the robotic rotary mill cutter 1 .
- the robotic rotary mill cutter 1 shows the position of the vertical Z-axis, and the 360-degree horizontal rotary W-axis, and the milling spindle swing arm pivotal Y-axis.
- FIGS. 2A and 2B depict the upper and lower portions, respectively, of the robotic rotary mill cutter of the preferred embodiment.
- a collar 2 is used to attach the umbilical cord (not shown) and cable (not shown) to the body of robotic rotary mill cutter 1 .
- Collar 2 may be exchanged to adapt to different size work strings (not shown). Additionally, the collar 2 provides a quick disconnect point in case emergency removal of the robotic rotary mill cutter 1 is necessary.
- locking hydraulic cylinders 3 are energized to lock the robotic rotary mill cutter 1 into the well bore (not shown).
- Z-axis hydraulic cylinder 6 is moved to a down position by extending piston rod 4 allowing the Z-axis slide 5 to extend. This permits the robotic rotary mill cutter 1 to begin cutting at the lowest point of the cut and be raised as needed to complete the severance.
- W-axis servo motor 8 rotates the W-axis rotating body 10 under control of the computer (not shown).
- W-axis rotating body 10 houses the milling spindle swing arm 14 and the milling spindle swing arm 14 is driven by motor 11 also housed in the W-axis rotating body 10 .
- Milling spindle swing arm 14 is driven by motor 11 through a half-shaft 12 such as Motorcraft model 6L2Z-3A427-AA.
- Half-shaft 12 has a C.V. joint (not shown) that allows milling spindle swing arm 14 to pivot in an arc from pivot bearing 13 that goes through W-axis rotating body 10 .
- Milling spindle swing arm 14 is moved by Y-axis hydraulic cylinder 16 .
- the rotation of W-axis rotating body 10 requires a swivel joint 9 , such as Rotary Systems Model DOXX Completion, to allow power and sense lines (not shown) to motor 11 , Y-axis hydraulic cylinder 16 , and load cell 54 sense wires (not shown).
- Cutting device 15 (for example, a carbide cutter) is mounted to the milling spindle swing arm 14 and is moved by Y-axis hydraulic cylinder 16 into the cut under computer control.
- FIG. 3 depicts an expanded view of one embodiment of an inserted carbide mill 17 that could be attached to milling spindle swing arm 14 .
- Other milling units with different material and/or cutting orientation could be utilized depending on the particular characteristics of the severance to be performed.
- FIG. 4A depicts a top view of nested multiple casings (tubulars) 18 that are positioned non-concentrically.
- FIG. 4B depicts an isometric view of nested multiple casings (tubulars) 18 that are positioned non-concentrically.
- FIG. 5A depicts a portion of the robotic rotary mill cutter 1 as it enters the nested multiple casings (tubulars) 18 .
- FIG. 5B shows the nested multiple casings (tubulars) 18 with the void that has been created by the robotic rotary mill cutter 1 .
- the profile generation system (not shown) simultaneously moved the robotic rotary mill cutter 1 in a vertical Z-axis, and a 360-degree horizontal rotary W-axis, and the milling spindle swing arm 14 in a pivotal Y-axis arc to allow cutting of the tubulars, cement (not shown), and formation rock (not shown) in any programmed shape or window profile(s) thereby cutting through the multiple casing (tubulars) 18 , cement (not shown) or other encountered material in casing annuli (not shown).
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Abstract
Description
Claims (63)
Priority Applications (5)
Application Number | Priority Date | Filing Date | Title |
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US12/540,924 US7823632B2 (en) | 2008-06-14 | 2009-08-13 | Method and apparatus for programmable robotic rotary mill cutting of multiple nested tubulars |
US12/878,738 US9175534B2 (en) | 2008-06-14 | 2010-09-09 | Method and apparatus for programmable robotic rotary mill cutting of multiple nested tubulars |
US14/381,184 US9759030B2 (en) | 2008-06-14 | 2011-12-15 | Method and apparatus for controlled or programmable cutting of multiple nested tubulars |
US14/931,100 US9745812B2 (en) | 2008-06-14 | 2015-11-03 | Method and apparatus for programmable robotic rotary mill cutting of multiple nested tubulars |
US15/688,075 US20180135373A1 (en) | 2008-06-14 | 2017-08-28 | Method and apparatus for programmable robotic rotary mill cutting of multiple nested tubulars |
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US13187408P | 2008-06-14 | 2008-06-14 | |
US12/484,211 US20090308605A1 (en) | 2008-06-14 | 2009-06-14 | Methodolgy and apparatus for programmable robotic rotary mill cutting of multiple nested tubulars |
US12/540,924 US7823632B2 (en) | 2008-06-14 | 2009-08-13 | Method and apparatus for programmable robotic rotary mill cutting of multiple nested tubulars |
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US12/484,211 Continuation-In-Part US20090308605A1 (en) | 2008-06-14 | 2009-06-14 | Methodolgy and apparatus for programmable robotic rotary mill cutting of multiple nested tubulars |
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Cited By (16)
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US20100288491A1 (en) * | 2009-05-14 | 2010-11-18 | Cochran Travis E | Subterranean Tubular Cutter with Depth of Cut Feature |
US20110209872A1 (en) * | 2008-06-14 | 2011-09-01 | Mcafee Wesley Mark | Method and apparatus for programmable robotic rotary mill cutting of multiple nested tubulars |
US20120018164A1 (en) * | 2010-07-22 | 2012-01-26 | Tabor William J | Clamp for a well tubular |
US20120261134A1 (en) * | 2011-04-15 | 2012-10-18 | Vetco Gray Inc. | Wellhead wicker repair tool |
US20130302104A1 (en) * | 2010-11-08 | 2013-11-14 | Starrag Ag | Device for Correcting the Position of Elements of a Machine Tool and Compensation Element Therefor |
US20140033885A1 (en) * | 2012-08-03 | 2014-02-06 | Baker Hughes Incorporated | Method of cutting a control line outside of a tubular |
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US10385638B2 (en) | 2014-12-23 | 2019-08-20 | Ga Drilling, A.S. | Method of removing materials by their disintegration by action of electric plasma |
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US20090308605A1 (en) * | 2008-06-14 | 2009-12-17 | Mcafee Wesley Mark | Methodolgy and apparatus for programmable robotic rotary mill cutting of multiple nested tubulars |
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